Distribution cabling tape and system

ABSTRACT

A distribution cabling tape comprises a resilient polymeric base sheet having a first major surface and a second major surface, the first major surface having a continuous lengthwise channel formed in a first portion thereof. The tape also includes an adhesive layer disposed on a second and third portion of the first major surface, the adhesive layer capable of adhering to a concrete or asphalt surface, such as a road, curb, or walkway.

PRIORITY APPLICATION

This application is a continuation of U.S. patent application Ser. No.16/816,546, filed on Mar. 12, 2020, which is a continuation of U.S.patent application Ser. No. 15/651,557, filed on Jul. 17, 2017, now U.S.Pat. No. 10,606,018, which claims the benefit of priority to 62/363,610,filed on Jul. 18, 2016, the content of which is relied upon andincorporated herein by reference in entirety.

BACKGROUND

The present invention is directed to a distribution cabling tape orprotective adhesive-backed structure and system for an asphalt orconcrete surface, such as a road, curb, or walkway, that protectscabling, wires, splices, and other telecommunications network devices.

Communications service providers are faced with increasing demands todeliver faster and better service to their customers. Service providerscan meet these needs for greater bandwidth by incorporating fiber opticsin the access network, the communication connection to the endsubscriber. Service providers have announced gigabit service offerings.

With many players competing in the industry, speed to build new networksis critical. However, the process to deploy traditional fiber opticnetworks often requires time consuming civil engineering work both inplanning, verifying existing infrastructure location and construction.The access network can be the most burdensome in that individual fibersmust connect each subscriber's living unit. In the case of single familyhome neighborhoods, that means a single fiber to each home.

For aerial deployments (telephone poles), deploying the fiber opticcable is relatively straight forward. Lashing the new fiber opticdistribution cable to existing telephone cabling or stringing a newmessenger wire in which to lash the new fiber optic cable is donerelatively quickly (about a day to install the distribution cable for aserving area of 200-500 homes). However, for new entrants forfiber-to-the-home (FTTh) service, gaining access to the telephone polesfrom the pole owner (often incumbent telephone company) can be a timeconsuming and litigious process.

For below grade deployments (conduit below grade in which to pull thedistribution cable) deployment can involve many construction machinesand operators for weeks for a serving area of 200-500 homes. One of themost time consuming operations is directional drilling to place theconduit below grade. The cost of directional drilling is approximately$40/foot making below grade fiber access network deployment cost muchmore than aerial deployments.

Therefore, need exists for a distribution cabling alternative totraditional aerial and below grade installations that can eliminate theneed to share telephone poles and avoid the time consuming and costlydirectional drilling for conduit placement.

SUMMARY

According to one embodiment of the present invention, a distributioncabling tape comprises a resilient polymeric base sheet having a firstmajor surface and a second major surface, the first major surface havinga continuous lengthwise channel formed in a first portion thereof. Thetape also includes an adhesive layer disposed on a second and thirdportion of the first major surface, the adhesive layer capable ofadhering to a concrete or asphalt surface.

According to another embodiment of the invention, a distribution cablingtape comprises a resilient polymeric base sheet having a first majorsurface and a second major surface. The tape further includes anadhesive layer disposed on first and second portions of the first majorsurface, the adhesive layer capable of adhering to an asphalt orconcrete surface, wherein the adhesive layer further includes acontinuous lengthwise channel formed therein, between the first andsecond portions along the first major surface, wherein the channel isconfigured to receive at least a portion of a distribution cable.

According to another embodiment of the invention, a distribution cablingtape comprises a resilient polymeric base sheet having a first majorsurface and a second major surface, the first major surface beingsubstantially continuous across a side to side width of the tape; and anadhesive layer disposed on a first and a second portion of the firstmajor surface, the adhesive layer capable of adhering to a concrete orasphalt surface, wherein the distribution cabling tape includes wingportions that taper to a narrower base sheet thickness at side ends ofthe distribution cabling tape.

According to another embodiment of the invention, a distribution cablingtape comprises a resilient polymeric base sheet having a first majorsurface and a second major surface, the first major surface beingsubstantially continuous across a side to side width of the tape,wherein the resilient polymeric base sheet comprises a composite of atleast two different materials; and an adhesive layer disposed on a firstand a second portion of the first major surface, the adhesive layercapable of adhering to a concrete or asphalt surface, wherein a portionof the distribution cabling tape is configured to receive at least aportion of at least one distribution cable.

According to another embodiment of the invention, a distribution cablingsystem comprises a distribution cabling tape having a resilientpolymeric base sheet having a first major surface and a second majorsurface, the first major surface having a continuous lengthwise firstchannel formed in a first portion thereof, and an adhesive layerdisposed on a second portion of the first major surface, the adhesivelayer capable of adhering to a concrete or asphalt surface. The systemfurther includes a second channel formed in the concrete or asphalt. Thesystem also includes a distribution cable at least partially disposed inboth the first and second channels.

The above summary of the present invention is not intended to describeeach illustrated embodiment or every implementation of the presentinvention. The figures and the detailed description that follows moreparticularly exemplify these embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further described with reference to theaccompanying drawings, wherein:

FIGS. 1A-1C and 1E-1I are cross section views of distribution cablingtapes according to different aspects of the invention and FIG. 1D is aperspective view of the adhesive backed road surface tape shown in FIG.1B.

FIGS. 2A-2D are cross section views of additional adhesive backed roadsurface tapes according to other aspects of the invention.

FIGS. 3A-3B are cross section views of additional adhesive backed roadsurface tapes according to other aspects of the invention.

FIG. 4 shows an example FTTh neighborhood network deployment accordingto yet another aspect of the invention.

FIGS. 5A-5C are top views of distribution cabling tapes according todifferent aspects of the invention.

FIG. 5D is an isometric view of distribution cabling tapes according toanother aspect of the invention.

While the invention is amenable to various modifications and alternativeforms, specifics thereof have been shown by way of example in thedrawings and will be described in detail. It should be understood,however, that the intention is not to limit the invention to theparticular embodiments described. On the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

In the following Detailed Description, reference is made to theaccompanying drawings, which form a part hereof, and in which is shownby way of illustration specific embodiments in which the invention maybe practiced. In this regard, directional terminology, such as “top,”“bottom,” “front,” “back,” “leading,” “forward,” “trailing,” etc., isused with reference to the orientation of the Figure(s) being described.Because components of embodiments of the present invention can bepositioned in a number of different orientations, the directionalterminology is used for purposes of illustration and is in no waylimiting. It is to be understood that other embodiments may be utilizedand structural or logical changes may be made without departing from thescope of the present invention.

The present invention is directed to a durable, protective distributioncabling tape that includes or covers a conduit for distribution cable,such as fiber optic network cable. The distribution cabling tape isconfigured to adhere to an asphalt or concrete surface, such as a road,curb, walkway, bridge support, building base or other foundation. In oneaspect, the distribution cabling tape comprises a pavement marking tapethat further includes a channel formed in the backing layer that isconfigured to receive at least a portion of a distribution cable. Inanother aspect, the distribution cabling tape comprises a pavementmarking tape that further includes a channel formed in the adhesivelayer that is configured to receive at least a portion of a distributioncable, which can include copper wire(s) and/or optical fiber(s). Inanother embodiment, the distribution cabling tape includes tapered wingportions that are less susceptible to damage and can accommodate a morecontoured road or other mounting surface. In another embodiment, thedistribution cabling tape can be formed from a composite material. Inyet another aspect, the distribution cabling tape houses a fiber opticcable within the construction of the tape. Optionally, the road, curb,or walkway surface may include a separate channel formed therein toreceive the distribution cable (or at least a portion thereof) and/orthe entire (or at least a portion of) adhesive-backed structure or tape.Other distribution cabling tapes can include some or all of theaforementioned features in combination.

FIG. 1A shows a first aspect of the invention, a distribution cablingtape 100 (also referred to herein as a road surface conduit) thatincludes a durable, resilient polymeric base sheet 110 having a firstmajor surface 114 and a second major surface 112. The first majorsurface 114 includes a continuous lengthwise channel 130 formed in afirst portion 114 a thereof. The channel 130 is configured to receive atleast a portion of a distribution cable, such as cable 150 shown in FIG.1C. While a single channel 130 is shown in FIG. 1A, in other aspects ofthe invention, a distribution cabling tape can include multiple channels(see e.g., FIG. 1E). In addition, tape 100 includes an adhesive layer120 disposed on a second portion 114 b and a third portion 114 c of thefirst major surface 114. In one aspect, the adhesive layer 120 comprisesa composition that is capable of adhering to a concrete or asphalt (orasphalt-concrete hybrid) surface, such as a road, curb or walkwaysurface, such as road 105 shown in FIG. 1C. In some aspects, the channel130 is adhesive free. In other aspects, the channel 130 may include someamount of adhesive in it to help hold the distribution cable in placeduring deployment. In another aspect, the adhesive layer 120 cancomprise a composition that is capable of adhering to an alternativeroad surface, such as a cobblestone or brick surface.

It is noted that while structure 100 is referred to herein as a “tape,”this term is not meant to exclude other types of adhesive-coatedstructures, such as adhesive-coated road patches, panels or markers thatcan provide a protective conduit or other type of pathway for cables. Inaddition, the distribution cabling tape can also provide a protectivepathway for electrical or power lines that are to be distributed througha neighborhood, or across a road, curb, street, parking lot or sidewalk,or for cabling repairs and/or splices. Moreover, the adhesive can beselected to provide either a temporary or more permanent type of bond tothe road, curb, or walkway, thus providing a distribution cablingsolution for short term events (such as concerts, sporting events,festivals, and the like), or for more longer duration deploymentsituations (such as subdivisions in development). In addition, while thetape embodiments described herein are often used in road, curb,sidewalk, or street applications, in alternative embodiments, thedistribution cabling tape can be used to distribute cabling along othersurfaces, such as along or up the side of a building, tower, bridge, orother structures. Further, while cable 150 is described herein as adistribution cable, tape 100 can be used to route and/or protect manydifferent types of cables, including communication cables, power cables(such as low voltage power cables), sensor wires, co-axial cables,signal cables, and other conventional cables, or other types ofequipment, such as sensors, RFID tags, embedded antennas, antenna feeds,and location markers.

FIG. 1B shows another aspect of the invention, a distribution cablingtape 100′ that includes a resilient polymeric base sheet 110 having afirst major surface 114 and a second major surface 112 that comprises apatterned surface 113 having a plurality of raised structures. The firstmajor surface 114 includes a continuous lengthwise channel 130 formed ina first portion 114 a thereof. The channel 130 is configured to receiveat least a portion of a distribution cable, such as cable 150 shown inFIG. 1C. While FIG. 1B shows that channel 130 is co-located with araised pattern structure, in other aspects, channel 130 may not beco-located with a raised pattern surface structure. In this aspect, thechannel 130 is co-located with a lengthwise raised structure 113 a sothat the overall height of the tape 100′ is not altered by the inclusionof the channel 130 and/or cable 150. In addition, tape 100′ includes anadhesive layer 120 disposed on a second portion 114 b and a thirdportion 114 c of the first major surface 114. The adhesive layercomprises a composition that is capable of adhering to a concrete orasphalt surface, such as a road, curb, or walkway surface, such as road105 shown in FIG. 1C. FIG. 1D is a perspective view of adhesive-backedstructure or tape 100′.

FIG. 1C shows another aspect of the invention, a distribution cablingtape 100″ that includes a resilient polymeric base sheet 110 having afirst major surface 114 and a second major surface 112 that comprises apatterned surface 113 having a plurality of raised structures. The firstmajor surface 114 includes a continuous lengthwise channel 130 formed ina first portion 114 a thereof. The channel 130 is configured to receiveat least a portion of a distribution cable 150. In this aspect, thedistribution cable 150 includes one or more electrical lines or opticalfibers 155. In some aspects, cable 150 can include one or more strengthmembers 152 a, 152 b, such as is present in commercially availablecable, such as 3M™ Clear Fiber Drop Cable (available from 3M Company,St. Paul Minn.), ROC™ Drop Dielectric Cable (available from CorningInc., Hickory N.C.). Other suitable cables include CampusLink™Indoor/Outdoor cable (available from Prysmian Group, Lexington, S.C.).In this aspect, the channel 130 may be co-located with a lengthwiseraised structure so that the overall height of the tape 100′ is notaltered. Alternatively, in some aspects, the distribution cable 150 cancomprise a conventional ribbon fiber having multiple fibers or a seriesof parallel optical fibers disposed on a filament tape to allowstraightforward access to separate individual fibers by peeling off aportion of the filament tape. As such, the distribution cable 150 canhave a circular, oval, or rectangular cross section profile. In otheralternative embodiments, channel 130 can be configured to accommodatemore than one distribution cable, such as cable 150.

In addition, tape 100″ includes an adhesive layer 120 disposed on asecond portion 114 b and a third portion 114 c of the first majorsurface 114. The adhesive layer comprises a composition that is capableof adhering to an asphalt or concrete surface, such as a road, curb, orwalkway surface 105.

FIG. 1E shows yet another aspect of the invention, a distributioncabling tape 100′″ that includes a resilient polymeric base sheet 110having a first major surface 114 and a second major surface 112 thatcomprises a patterned surface 113 having a plurality of raisedstructures. The first major surface 114 includes multiple continuouslengthwise channels, 130 a, 130 b, and 130 c formed in a first portionthereof. Of course, depending on the application, a fewer number (e.g.,2) or a greater number (e.g., 4, 5) of channels can be formed in thefirst major surface of the base sheet 110. The channels 130 a-130 c areeach configured to receive at least a portion of a distribution cable,such as cable 150 shown in FIG. 1C. While FIG. 1E shows that channels130 a-130 c are each co-located with a raised pattern structure, inother aspects, channels 130 a-130 c may not be co-located with a raisedpattern surface structure in other embodiments. In this aspect, thechannels 130 a-130 c are each co-located with a lengthwise raisedstructure so that the overall height of the tape 110′″ is not altered bythe inclusion of the channels 130 a-130 c and/or the inserted cables. Inaddition, tape 100′″ includes an adhesive layer 120 disposed onremaining portions of the first major surface 114. The adhesive layercomprises a composition that is capable of adhering to a concrete orasphalt surface, such as a road, curb, or walkway surface, such as road105 shown in FIG. 1C.

FIG. 1F shows another aspect of the invention, a distribution cablingtape 100 iv that includes a resilient polymeric base sheet 110 having afirst major surface 114 and a second major surface 112. In thisembodiment, the first major surface 114 is substantially continuousacross the side to side width of the tape 100 iv. In this embodiment, afirst portion 114 a of the surface 114 is not covered with an adhesivelayer. In an alternative embodiment, first portion 114 a can be coatedwith an adhesive layer.

The portion 114 a is configured to accommodate at least a portion of atleast one distribution cable, such as cable 150, similar to thosedescribed above. In addition, tape 100 iv includes an adhesive layer 120disposed on a second portion 114 b and a third portion 114 c of thefirst major surface 114. The adhesive layer comprises a composition thatis capable of adhering to a concrete or asphalt surface, such as a road,curb, or walkway surface, such as road 105 shown in FIG. 1C. Further, inthis embodiment, tape 100 iv includes wing portions 116 a and 116 b thattaper to a narrower base sheet thickness at the tape side ends. In thismanner, the outer edges of the tape can be less susceptible to damageand can accommodate a more contoured road or other mounting surface.

In an alternative embodiment, resilient polymeric base sheet 110 can beformed from a single material, or, alternatively, different materials.For example, as shown in FIG. 1F, a first portion 110 a of polymericbase sheet 110 can be formed from a first material, such as a toughenedor semi-rigid polymer material and second and third portions 110 b, 110c of polymeric base sheet 110 can be formed from a different material,such as a more flexible elastomeric (lower modulus) material. Such acomposite base sheet 110 can be formed by coextruding the two differentpolymers, as would be apparent to one of skill in the art given thepresent description.

FIG. 1G shows another aspect of the invention, a distribution cablingtape 100 v that includes a resilient polymeric base sheet 110 having afirst major surface 114 and a second major surface 112 that comprises apatterned surface 113 having a plurality of raised structures. Theresilient polymeric base sheet 110 can be formed from a single materialor a coextrusion of multiple materials, such as described above.

In this embodiment of FIG. 1F, the first major surface 114 issubstantially continuous across the side to side width of the tape 100v. A first portion 114 a of the surface 114 is not covered with anadhesive layer. First portion 114 a can accommodate at least a portionof a distribution cable, such as cable 150, similar to those describedabove. In alternative embodiments, raised structures can be included (ornot included) over the tape region covering cable 150. In addition, tape100 v includes an adhesive layer 120 disposed on a second portion 114 band a third portion 114 c of the first major surface 114. The adhesivelayer comprises a composition that is capable of adhering to a concreteor asphalt surface, such as a road, curb, or walkway surface, such asroad 105 shown in FIG. 1C. Further, in this embodiment, tape 100 vincludes wing portions 116 a and 116 b that taper to a narrower basesheet thickness at the tape side ends. In this manner, the outer edgesof the tape can be less susceptible to damage and can accommodate a morecontoured road or other mounting surface.

FIG. 1H shows another aspect of the invention, a distribution cablingtape 100 vi that includes a resilient polymeric base sheet 110 having afirst major surface 114 and a second major surface 112 that comprises apatterned surface 113 having a plurality of raised structures. Inalternative aspects, resilient polymeric base sheet 110 can be formedfrom a single material, or, alternatively, different materials, such asdescribed above. In this embodiment, the first major surface 114 issubstantially continuous across the side to side width of the tape 100vi. A first portion 114 a of the surface 114 is not covered with anadhesive layer. First portion 114 a can accommodate at least a portionof at least one distribution cable, such as cable 150, similar to thosedescribed above. In this embodiment, raised structures are present overthe tape region covering cable 150. In addition, tape 100 vi includes anadhesive layer 120 disposed on a second portion 114 b and a thirdportion 114 c of the first major surface 114. The adhesive layercomprises a composition that is capable of adhering to a concrete orasphalt surface, such as a road, curb, or walkway surface, such as road105 shown in FIG. 1C.

FIG. 1I shows another aspect of the invention, a distribution cablingtape 100 vii that includes a resilient polymeric base sheet 110 having afirst major surface 114 and a second major surface 112 that comprises apatterned surface 113 having a plurality of raised structures. However,in this aspect, one or more of the raised structures, such as structure113 a, are milled down to provide an overall flatter upper surface. Inalternative aspects, resilient polymeric base sheet 110 can be formedfrom a single material, or, alternatively, different materials, such asdescribed above. In this embodiment, the first major surface 114 issubstantially continuous across the side to side width of the tape 100vii and is covered with an adhesive layer 120 that is capable ofadhering to a concrete or asphalt surface, such as a road, curb, orwalkway surface, such as road 105 shown in FIG. 1C. A first portion 114a of the surface 114 may be covered with an adhesive layer 120. Firstportion 114 a can accommodate at least a portion of at least onedistribution cable, such as cable 150 a, similar to those describedabove.

In more detail, applied to the bottom surface 114 of the base sheet 110is an adhesive 120, such as a pressure sensitive adhesive (PSA). In oneaspect, the PSA 120 is designed to adhere to a common road, curb, orwalkway surface, such as concrete and asphalt surfaces, and to withstandthe wide temperature variations, weather and chemicals present. Forexample, acceptable PSA formulations are described in U.S. Pat. Nos.5,906,889 and 5,453,320, each of which is incorporated by referenceherein in its entirety. In another aspect, the adhesive can comprise aheat activated adhesive. In addition, other types of adhesives can beused, depending on the duration of the intended deployment of thedistribution cabling tape.

The adhesive layer 120 is applied to a resilient base sheet 110. Sheet110 has a top surface 112 and a bottom surface 114. One or more portionsof the bottom surface 114, such as portions 114 b and 114 c are incontact with the adhesive layer 120. In one aspect, the base sheet 110can be made from non-crosslinked elastomer precursors. The base sheet110 is preferably made of a durable construction to withstand continualimpacts made by vehicles and/or pedestrians. Acceptable base sheetcompositions have been described in, for example, U.S. Pat. Nos.4,117,192, 4,490,432, 4,282,281, US 2014/0011911, and U.S. Pat. No.5,853,846, each of which is incorporated by reference herein in itsentirety. In one aspect, the base sheet can comprise a thermoplasticmaterial.

In some other aspects, the base sheet can comprise a more conformablematerial, such that when the distribution cable is inserted in achannel, the channel can conform about an outer shape or profile of thedistribution cable, for example, after the distribution cable isinserted in the channel, or after the distribution cable is installed onthe road surface. In a further alternative aspect, the base sheet cancomprise a fabric material, or a scrim, such as is described in U.S.Pat. Nos. 7,169,831 and 5,981,033, each of which is incorporated byreference herein in its entirety, which can make the distributioncabling tape removable in a straightforward manner, which can be usefulin temporary deployment applications, such as for short duration eventsor in repair applications. In addition, as mentioned above, the basesheet can also comprise a composite of different materials, such asdifferent polymeric materials. For example, a composite base sheet canbe formed by coextruding two different polymers, such as a toughened orsemi-rigid polymer material and a more flexible elastomeric (lowermodulus) material.

The second or top layer 112 of the base sheet 110, may be a flat surface(such as shown in FIG. 1A) or it may have a raised pattern surface 113(such as is shown in FIG. 1B). The base sheet 110 can be any color sothat the tape can stand out (such as including white or yellow coloring)or it can blend into the surface upon which it is mounted (such asincluding gray or black coloring) or it can be covered with conventionalroad surfacing or resurfacing materials. Retroreflective elements, glassand/or ceramic beads, can be embedded directly on the second surface 112as is described in U.S. Pat. No. 4,388,359, which is incorporated byreference in its entirety. Alternatively, the second surface 112 can becoated with either a thermoplastic or thermosetting layer. For flatmarkings, an example of a thermoplastic material is described in U.S.Pat. No. 4,117,192, which is incorporated by reference in its entirety,and for thermosetting an example material is described in U.S. Pat. No.5,077,117, which is incorporated by reference in its entirety. For basesheets 110 having a plurality of raised protuberances, example materialsare described in U.S. Pat. Nos. 4,988,541, 5,683,746, 5,593,246,6,479,132, 5,928,761, 5,227,221, and 5,763,000, each of which isincorporated by reference in its entirety. Additionally, other patternsand designs of raised protuberances are described in U.S. Pat. Nos.4,388,359, 4,988,541, 5,683,746, and 4,681,401, each of which isincorporated by reference in its entirety. For applications where roadsmay be subject to snow and ice accumulation, exemplary base sheetsdesigned to resist the action of snowplow blades are described in U.S.Pat. Nos. 4,129,673, 4,685,824, and 6,431,788, each of which isincorporated by reference in its entirety. Exemplary commerciallyavailable pavement marking tapes include those sold under the Stamark™brand, including 380 IES and 380 AW models, available from 3M Company,St. Paul Minn.

Acceptable methods of forming a tape structure using the exemplary basesheets and adhesives described herein can include hot embossing, doublesided embossing, patterned nip rolls, doctor blading (for adhesives),and pattern coating techniques. For example, patterned embossing rollscan be brought into contact with opposing sides of a web of the basesheet material to generate the desired patterns on each side of the basesheet (e.g., diamonds on the air side (e.g., surface 112) and continuouschannel on the road side (e.g., surface 114)). Doctor blades or patterncoating can be used to apply adhesives in non-channel areas.

FIG. 2A shows another aspect of the invention, a distribution cablingtape 200 that includes a resilient polymeric base sheet 210 having afirst major surface 214 and a second major surface 212 that comprises apatterned surface 213 having a plurality of raised structures. In thisaspect, a distribution cable 250 is embedded in the tape 200. Forexample, in alternate configurations, the distribution cable 250 can beembedded between the first major surface 214 and the adhesive layer 220,the distribution cable 250 can be embedded within the adhesive layer220, or the distribution cable 250 can be embedded between the adhesivelayer 220 and the road surface 205. Preferably, in this aspect, thedistribution cable 250 can be a low profile fiber cable, such as a fiberribbon cable, having a plurality of optical fibers (in this example,fibers 250 a-250 g). Although not shown, distribution cable 250 caninclude additional strength members (e.g., Kevlar yarn or glass fiberrods (FRP)) to help reduce axial strain on the fiber as the road expandsand/contracts with daytime heating and seasonal temperature variations.The adhesive layer 220 and the base sheet 210 can be constructed asdescribed above.

FIG. 2B shows another aspect of the invention, a distribution cablingtape 200′ that includes a resilient polymeric base sheet 210 having afirst major surface 214 and a second major surface 212 that comprises apatterned surface 213 having a plurality of raised structures. Inaddition, tape 200′ includes an adhesive layer 220 disposed on a firstportion 214 a and a second portion 214 b of the first major surface 214.The adhesive layer comprises a composition that is capable of adheringto an asphalt or concrete surface, such as road, curb, or walkwaysurface 205. In this aspect, a gap 220 a is formed between adhesivesections that is adhesive free and is configured to receive adistribution cable 250, or at least a portion thereof. Preferably, inthis aspect, the distribution cable 250 can be a low profile fibercable, such as a fiber ribbon cable, having a plurality of opticalfibers. The adhesive layer 220 and the base sheet 210 can be constructedas described above.

FIG. 2C shows yet another aspect of the invention, a distributioncabling tape 200″ that includes a resilient polymeric base sheet 210having a first major surface 214 and a second major surface 212 thatcomprises a patterned surface 213 having a plurality of raisedstructures. In addition, tape 200″ includes an adhesive layer 220disposed on the first major surface 214. The adhesive layer comprises acomposition that is capable of adhering to a road, curb, or walkwaysurface 205. In this aspect, a relatively shallow surface channel 207 isformed in the road, curb, or walkway surface 205. A distribution cable250 can be received in channel 207 and the tape 200″ can be disposeddirectly above the surface channel 207. The channel 207 can be formedwith a conventional road surface grinding tool, such as are availablefrom Smith Manufacturing (Pompano Beach, Fla.). In one example, thesurface channel 207 can have a width and depth of about ¼″-1″ to receivea conventional fiber drop cable, such as the ROC™ Drop Dielectric Cable(available from Corning Inc., Hickory N.C.). In this aspect, the channelor pathway can have a width and depth sufficient to allow thedistribution cable to “float” within the pathway as the road expands andcontracts with daytime heating and seasonal temperature changes.Optionally, in addition to the distribution cable 250, in some aspectsof the invention, a sealant or adhesive can be applied to the surfacechannel 207. For example, an added sealant can help prevent waterbuild-up within the surface channel. An exemplary sealant can comprise,for example, Safetrack™ MTI sealant available from StirlingLloydPolychem Ltd (UK). The adhesive layer 220 and the base sheet 210 can beconstructed as described above.

Further, different sections of surface channel 207 can be configuredwith a different shape, such as a wider channel or trench, so as toaccommodate different types of network devices, such as splices or otherequipment.

It is noted that if a distribution cable of a certain size were placedunder a road surface tape that did not include a channel therein or ifthere were no channel or trench formed in the road surface, the tapewould likely bulge at the cable location. This protrusion wouldconcentrate the tire load onto the distribution cable and would likelycause premature wear of the road surface tape in this region.

FIG. 2D shows yet another aspect of the invention, a distributioncabling tape 200′″ that includes a resilient polymeric base sheet 210having a first major surface 214 and a second major surface 212 thatcomprises a patterned surface 213 having a plurality of raisedstructures. In addition, the first major surface 214 includes acontinuous lengthwise channel 230 formed in a first portion thereof. Thechannel 230 is configured to receive at least a portion of adistribution cable 250. In this aspect, the distribution cable 250includes one or more electrical lines or optical fibers and can comprisea cable such as those described above. An adhesive layer 220 disposed onthe first major surface 214 on one or both sides of channel 230. Theadhesive layer comprises a composition that is capable of adhering to aroad or walkway surface 205. In this aspect, a relatively shallowsurface channel 207 is formed in the road or walkway surface 205. Thetape 200′″ can be disposed directly above the surface channel 207 suchthat distribution cable 250 can be received in the spaced defined bychannel 230 and channel 207. The channel 207 can be formed with aconventional road surface grinding tool, such as those described above.The adhesive layer 220 and the base sheet 210 can be constructed asdescribed above. Alternatively, as would be apparent to one of skill inthe art given the present description, tape 200′″ can be furthermodified to include multiple channels (see e.g., FIG. 1E) and roadsurface 207 can also include multiple channels, as appropriate.

In a further alternative, a distribution cabling tape that does notinclude a channel formed in the base sheet and that is adhesive freeover a central portion of the first major surface (see e.g., tape 200′)can be placed over a road surface channel 207 to provide a protectivecovering for a distribution cable 250 installed in channel 207.

FIG. 3A shows yet another aspect of the invention, a distributioncabling tape 300 that includes a resilient polymeric base sheet 310having a first major surface 314 and a second major surface 312 thatcomprises a patterned surface 313 having a plurality of raisedstructures. In this aspect, a distribution cable 350 is embedded in thetape 300, such as is described above with respect to FIG. 2A. Forexample, in alternate configurations, the distribution cable 350 can beembedded between the first major surface 314 and the adhesive layer 320,the distribution cable 350 can be embedded within the adhesive layer320, or the distribution cable 350 can be embedded between the adhesivelayer 320 and the road surface. The adhesive layer 320 and the basesheet 310 can be constructed as described above. Further, in this aspectof the invention, the road surface 305 includes a wide trench 308 thatis configured in depth and width to receive the entire width of the tape300, such that the top surface 312 is substantially at road surfacelevel. In this manner, especially for environments where ice and snowaccumulation are common, the tape 300, and thus the distribution cable350, can be protected from snow plows and other road surface servicingequipment.

In a further alternative aspect, a distribution cabling tape 300 can beconstructed as shown in any of the above tape constructions. Forexample, as is shown in FIG. 3B, a distribution cabling tape 300′includes a resilient polymeric base sheet 310 having a first majorsurface 314 and a second major surface 312 that comprises a patternedsurface 313 having a plurality of raised structures. In addition, tape300′ includes an adhesive layer 320 disposed on the first major surface314. The adhesive layer comprises a composition that is capable ofadhering to a concrete or asphalt surface, such as a road, curb, orwalkway surface 305. In this aspect, the road surface 305 includes awide trench 308 that is configured in depth and width to receive theentire width of the tape 300′, such that the top surface 312 issubstantially at road surface level. In addition, a second, narrowershallow channel 307 is formed in the bottom surface of trench 308 suchthat a distribution cable 350 can be received in channel 307 and thetape 300′ can be disposed directly above the channel 307. The trench 308and channel 307 can be formed with conventional road surface grindingtools. In a further alternative aspect, additional channels or trenchescan be utilized to accommodate splices or extra fiber(s) to accommodatestrain and future repairs.

In a further aspect of the invention, a distribution cabling tape can beformed having a curved channel or curved break-out channels to allow forcables to exit the distribution cabling tape in any direction. Forexample, FIG. 5A shows a distribution cabling tape 500. In thisconfiguration, tape 500 is configured as a patch to accommodate a rightangle turn. In this aspect, channel 530, which can be formed in a firstmajor surface of the backing sheet (such as is described previously) caninclude a curved portion 531, which allows a distribution cable to entera first side 504 a and exit an adjacent side 504 b. Alternatively, thechannel 530 can be curved at a different angle than a right angle,depending on the cable routing application. Optionally, the road surfacecan also include a corresponding curved channel.

In a further alternative, a distribution cabling tape can includeseveral break-out channels that can allow one or more communication orpower lines within the distribution cable to branch out from the maincable. For example, FIGS. 5B and 5C shows a distribution cabling tape500′. In FIG. 5B, tape 500′ is configured as a patch to accommodate oneor more branch outs (e.g., substantially right angle turns). In thisaspect, the channel 530, which can be formed in a first major surface ofthe backing sheet (such as is described previously), can include a mainchannel 530 a and multiple branches 530 b and 530 c. In thisconfiguration, a distribution cable entering a first side 504 a can haveat least one communication line branch out from the main cable and exitan adjacent side 504 b or 504 c, with the remainder of the communicationlines continuing towards side 504 d. In FIG. 5C, tape 500′ is configuredas a tape having a length L much greater than its width W. In FIG. 5C,tape 500′ includes repeating branching sections (three such sections areshown in the figure), with branches 530 b-530 g providing branchinglocations for communication lines within the main distribution cable.

In a further aspect of the invention, multiple distribution cablingtapes can be used to route a distribution cable over multiple surfaces.As shown in FIG. 5D, a first distribution cabling tape 500 a, adistribution cabling patch 500 b, and a second distribution cabling tape500 c can be used to route a distribution cable (not shown) from a roadsurface 505 across and along a curb 506. For example, a distributioncable can be routed along channel 530 a to a patch 500 b mounted at curb506. One or more communication lines can be routed along channel 530 bto curved channel 530 c and then along channel 530 d of distributioncabling tape 500 c.

As would be understood by one of ordinary skill in the art given thepresent description, a cable routing deployment (in a neighborhood orother venue) can use any number of combinations of the distributioncabling tapes and patches described herein. Further, the continuouschannels formed in the tapes and road surfaces need not be formed asstraight lines. Additionally, the distribution cabling tape or roadsurface may include a loop shaped channel or trench configured toaccommodate slack storage for future repairs.

The distribution cabling tape embodiments described herein can beemployed as part of a fiber access network and provide a cost effectiveand rapidly deployable alternative to traditional fiber-to-the-home,building, or event site methods. For example, one such applicationemploying the distribution cabling tape embodiments described herein fora communications application is shown in FIG. 4. Network 401 is providedto a neighborhood having a plurality of homes. In this aspect of theinvention, the telecommunications cabling can be provided on the roadsurface using one or more of the road surface conduit structuresdescribed above. In this aspect, traditional telecommunications cabling,such as fiber drop cables, can be used in the road surface conduit.Shallow grooves, such as groove 207 described above in FIG. 2C, areground into the road surface 405 in the pathways shown in FIG. 4.Distribution cable 450 bring fibers from the central office to eachterminal 460 using road surface conduit 400 a. Inside the terminal, dropcables 451 are connected to the appropriate distribution fiber and runto each home via one or more road surface conduits 400 b-400 d. In moredetail, drop cables 451 that need to run across the street can again belaid in a road surface groove and protected/encased by any of roadsurface conduits 400 b-400 d.

In one aspect, the distribution cable 450 can have be a fiber countsuitable for a centralized split FTTh architecture (e.g., 144 fiber) ora fiber count suitable for a distributed split FTTh architecture (e.g.,12 fiber). Example fiber cabling includes MiniXtend 144ZM4-T4F22A20(available from Corning Inc.) that is broken out to single fiber dropsin the terminal. A suitable smaller fiber count cable includes Mini LTFlat Drop AT-5BE8T7X-12 (available from OFS) that is power split to thesingle fiber drops in the terminal. In either case, a conventional dropcable 451 can include a Mini LT Flat Drop AT-5BE8T7X-1 or 2 (availablefrom OFS). The adhesive backed structure or tape 400 a-400 d can have adurable construction, similar to the backing/adhesive constructionsdescribed above. As such, the adhesive backed structure or tape 400a-400 d provide cable protection for an extended period of time, even ifused on a temporary basis, until a traditional underground conduit isinstalled. In addition, the distribution cabling tape can be used forrepairing faults. For example, if a fault was discovered, the originaldistribution cabling tape can be removed at the fault location, a repairsplice to the line or lines can be made at that location, and a new tapeor tape section can be applied to cover the splice or repair.

In addition, it is expected that a road surface may undergo significantshifts and cracks which could severely stress the distribution cable. Assuch, in some aspects, an excess distribution cable length can beprovided during installation. In one example, the cable would purposelybe applied with a, e.g., sinusoid pattern so that it has 1-2% excesslength. When the road surface shifts, this region of cable would bestrained into a sine wave of reduced amplitude, or become substantiallystraight.

The distribution cabling tape thus allows a service provider theopportunity to quickly connect a sufficient number of customers in aneighborhood or building before making a large infrastructureinvestment. In this manner, each of the houses in this area of theneighborhood can be rapidly accessed without having to utilizedirectional drilling or other massive road destruction and repairprocedures.

Other applications for the tape constructions described herein can alsobe implemented. For example, the adhesive backed structure or tape canbe configured to further ruggedize drop cable for direct buriedapplications. The tape can continue off the road and can be wrappedaround the drop cable making a robust transition from the road surfaceto below grade bury of the cable and continuing all the way to the houseif deemed necessary. In addition, the road surface conduit can bedeployed on a curb adjacent to the street thereby eliminating networkdisruption when the street is resurfaced. The road surface conduit canbe deployed with pre-fabricated distribution cable assemblies (e.g.,FlexNap, available from Corning, Inc.) where the access branch point isaccommodated in the road surface. An alternative deployment techniquecan include utilizing a RetractaNet™ cable (available from PrysmianGroup, Lexington, S.C.) and one or more window cuts to access one ormore of the individual communication lines therein. In addition, thedistribution cabling tape embodiments described herein can be used todistribute cabling along other surfaces, such as along or up the side ofa building, tower, bridge, or other structures.

While a preferred application of the distribution cabling tape is fortelecommunication applications, as mentioned previously, otherapplications can include pathways for power, sensors or sensing orelectronics for smart road applications.

Experiment

In a first experiment, 28 samples of the various configurationsdescribed above were prepared in short sections and tested on a vehiclewear simulator (VWS). The VWS can include a drum covered with anappropriate surface material to simulate, e.g., highway pavement. A cartire loaded at 1000 pounds is pressed against the drum. The VWS can berun at about 120 RPM, corresponding to approximately 50 mph, and at aconstant temperature (e.g., 35° C.) for about 10 hours to simulatevehicle tire hits.

Samples were applied to the road surfaces with fiber optic cables in thetest apparatus. Simulated tire hits over the samples were conducted andfiber continuity was observed at increasing intervals of simulated tirehits. The results from this testing showed no fiber breaks for all ofthe configurations tested to 1 million tire hits.

In another experiment, a freeze-thaw test was conducted on anothersample that was configured in a manner consistent with that shown inFIG. 2C, described above. In this experiment, a concrete block wasgrooved with a ¼″ wide by ¼″ deep groove. A section of Corning ROCcable, 001EB1-14701DF9, was laid in the groove and a road surface tapewas applied over the cable to encase the fiber optic cable similar tothat shown in FIG. 2C. The sample was placed in a metal tub and coveredwith water. The tub was placed in an environmental chamber from −30° C.freezing conditions to +60° C. thawing conditions. The sample wascompletely frozen and completely thawed several times with no disruptionof the road tape, fiber optical cable or concrete block.

Various modifications, equivalent processes, as well as numerousstructures to which the present invention may be applicable will bereadily apparent to those of skill in the art to which the presentinvention is directed upon review of the present specification.

We claim:
 1. A method of deploying a communications network, the methodcomprising: forming a trench in a road surface having a width and abottom surface that is below surface level of the road; forming achannel in the bottom surface of the trench, the channel being narrowerthan the width of the trench; deploying a distribution cable into thechannel; and disposing a distribution cabling tape into the trenchdirectly above the channel.
 2. The method of claim 1, wherein thedistribution cabling tape comprises a resilient polymeric base sheethaving a first major surface and a second major surface, and an adhesivelayer disposed on the first major surface, the adhesive layer capable ofadhering to the road surface.
 3. The method of claim 2, wherein thesecond major surface of the distribution cabling tape comprises apatterned surface having a plurality of raised structures.
 4. The methodof claim 3, wherein the second major surface of the distribution cablingtape comprises a coated surface.
 5. The method of claim 4, wherein thecoated surface comprises a surface coated with at least one of athermoset, a thermoplastic, and retroreflective elements.
 6. The methodof claim 1, wherein the road surface comprises concrete or asphalt. 7.The method of claim 1, wherein the distribution cable comprises at leastone optical fiber.
 8. The method of claim 1, wherein the distributioncable is a pre-fabricated distribution cable assembly.
 9. The method ofclaim 1, wherein the trench and the channel are formed using roadsurface grinding tools.
 10. The method of claim 1, wherein the roadsurface is a road, curb or walkway.
 11. The method of claim 1, furthercomprising: applying a sealant or an adhesive to the channel that canhelp prevent water build-up in the channel.
 12. The method of claim 1,wherein the distribution cabling tape includes several break-outchannels to allow one or more communication or power lines within thedistribution cable to branch out from the distribution cable.
 13. Themethod of claim 1, wherein the distribution cable tape continues beyondthe road surface, the method further comprising: wrapping thedistribution cable tape extending beyond the road surface around thedistribution cable.